Barrier Laminates and Methods of Making the Same

ABSTRACT

Articles comprising an outer fabric layer and a laminate are provided. The laminate may include a barrier film layer and an inner fabric layer, in which the outer fabric layer at least partially encircles and overlies the laminate. The outer fabric layer comprises an outer fabric layer seal and the laminate comprises a laminate seal that is separate and distinct from the outer fabric seal. The articles may be devoid of any bonds between the outer fabric layer and the laminate.

PRIORITY CLAIM

This application is a divisional of U.S. Non-Provisional applicationSer. No. 15/620,921 filed Jun. 13, 2017, which claims priority under 35U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 62/349,725,filed on Jun. 14, 2016, which is expressly incorporated by referenceherein in its entirety.

TECHNICAL FIELD

Embodiments of the presently-disclosed invention relate generally tobarrier laminates (e.g., trilaminates) comprising an outer fabric layerand a laminate (e.g., a bilaminate) including a barrier film layer andan inner fabric layer, in which the outer fabric layer at leastpartially encircles and overlies the laminate.

BACKGROUND

According to Association for the Advancement of Medical Instrumentation(AAMI), surgical gowns are classified into 4 categories (i.e., AAMI 1,2, 3 and 4, with AAMI 4 providing the highest protective level).

Barrier laminates suitable for AAMI 4-rated barrier laminates (e.g.,surgical gowns) must pass stringent tests that evaluate barrierproperties and whether the exhibited barrier properties would preventbody fluid and viral penetration, for example, while keeping a highlevel of breathability to ensure a wearer's comfort. These tests areknown as ASTM F1670 and F1671. For a barrier laminate to be suitable foruse as an AAMI 4-rated barrier laminate for use in construction of, forexample, surgical gowns, the gown chest and its sleeves must eachsuccessfully pass these tests. Furthermore, the seam areas of sleevesmust also pass these tests.

For some barrier laminate materials (e.g., having anonwoven-film-nonwoven structure), however, impermeable seams formedfrom the barrier laminate materials is difficult to consistently offerwhile using a thermal bonding method known as heat sealing. Less thandesirable seam barrier properties may occur when the basis weight of,for example, when material incompatibility between the film forming thecore of the barrier laminate and the nonwoven layers forming the skinsof the barrier laminate.

Therefore, there remains a need in the art for articles (e.g., formed ofbarrier laminates in the form of surgical gowns, sleeves, surgicaldrapes, pant legs, etc.) including seams providing excellent barrierproperties and methods of making such articles.

SUMMARY OF INVENTION

One or more embodiments of the invention may address one or more of theaforementioned problems. Certain embodiments according to the inventionprovide articles, such as barrier laminates that may be provided in avariety of geometric forms, that include (i) an outer fabric layerincluding an outer fabric layer seal formed between a first outer fabriclayer side and a second outer fabric layer side to provide a hollowouter fabric layer structure defining an outer fabric layer conduit and(ii) a laminate, which may be at least partially encircled by the outerfabric layer and located within the hollow outer fabric layer structure,including a barrier film layer and an inner fabric layer. The laminatemay comprise a laminate seal, which is separate and distinct from theouter fabric layer seal, formed between a first laminate side and asecond laminate side to provide a hollow laminate structure defining alaminate conduit. In this regard, embodiments of the invention comprisearticles (e.g., barrier laminates) including two separate and distinctseals to provide articles with seams exhibiting improved seam barrierproperties. For example, the configuration using two separate anddistinct seals, as discussed herein, eliminate seam failure issuesrelated to, at least, material incompatibility issues between anoutermost fabric layer and a core barrier layer as realized bytraditional articles formed from barrier laminates (e.g.,nonwoven-film-nonwoven barrier laminates).

In one aspect, the invention provides articles (e.g., barrier laminatesin the form of surgical gowns, sleeves, surgical drapes, pant legs,etc.) comprising an outer fabric layer and a laminate comprising atleast a barrier film layer and an inner fabric layer, in which the outerfabric layer at least partially encircles and overlies the laminate. Inaccordance with certain embodiments of the invention, the barrier filmlayer may be located either directly or indirectly between the outerfabric layer and the inner fabric layer. For example, articles maycomprise a trilaminate including the barrier film layer directlyadjacent to and sandwiched between both the outer fabric layer and theinner fabric layer. In accordance with certain embodiments of theinvention, the articles may be devoid of bonds (e.g., mechanical bonds,thermal bonds, etc.) between the outer fabric layer and the laminate. Asnoted above, the outer fabric layer may comprise an outer fabric layerseal formed between a first outer fabric layer side and a second outerfabric layer side to provide a hollow outer fabric layer structuredefining an outer fabric layer conduit and the laminate may comprise alaminate seal, which is separate and distinct from the outer fabriclayer seal, formed between a first laminate side and a second laminateside to provide a hollow laminate structure defining a laminate conduit.In this regard, certain embodiments of the invention may comprise twoseparate and distinct seals, while the outer fabric layer and thelaminate (e.g., bilaminate encircled by the outer fabric layer) may notbe bonded to each other (e.g., devoid of bonds therebetween). Certainembodiments of the present invention mitigate or eliminateincompatibility issues often associated with seals (e.g., seamsincluding a seal) of traditional barrier articles (e.g., barrierlaminates) having a nonwoven-film-nonwoven structure. Certainembodiments of the invention provide barrier articles suitable forpassing synthetic blood barrier testing (F1670) and viral barriertesting (F1671).

In another aspect, the present invention provides a method of makingbarrier laminates (and articles comprising such barrier laminates).Methods, in accordance with certain embodiments of the invention,comprise a step of providing an outer fabric layer, in which the outerfabric layer includes a first outer fabric layer side, a second outerfabric layer side, a first outer fabric layer end, and a second outerfabric layer end. The methods may also comprise a step of forming ahollow outer fabric layer structure (e.g., a sleeve or tube structure)comprising an outer fabric layer conduit by bonding the first outerfabric layer side to the second outer fabric layer side to form an outerfabric layer seal extending from the first outer fabric layer end to thesecond outer fabric layer end. The methods may also comprise a step ofproviding a laminate including a barrier film layer and an inner fabriclayer, in which the laminate includes a first laminate side, a secondlaminate side, a first laminate end, and a second laminate end. Inaccordance with certain embodiments of the invention, the methods maycomprise encircling the hollow outer fabric layer structure with thelaminate, in which the barrier layer film is located either directly orindirectly between the outer fabric layer and the inner fabric layer.The methods may also comprise a step of forming a hollow laminatestructure (e.g., a sleeve or tube structure) comprising a laminateconduit by bonding the first laminate side to the second laminate sideto form a laminate seal extending from the first laminate end to thesecond laminate end to form an intermediate barrier laminate, in whichthe hollow laminate structure encircles (e.g., concentrically encircles)the hollow outer fabric layer structure. In this regard, certainembodiments of the invention may comprise separately forming the hollowouter fabric layer structure (e.g., a sleeve or tube structure) and thehollow laminate structure (e.g., a sleeve or tube structure) followed byinserting the hollow outer fabric layer structure inside the hollowlaminate structure such that the hollow outer fabric layer structure isencircled by the hollow laminate structure to form the intermediatebarrier laminate. Methods, in accordance with certain embodiments of theinvention, may comprise a step of inverting the intermediate barrierlaminate (e.g., turning the intermediate barrier laminate inside-out) toform the barrier laminate, in which the outer fabric layer encircles thelaminate at the completion of the inverting step.

BRIEF DESCRIPTION OF THE DRAWING(S)

The invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the invention are shown. Indeed, this invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout, andwherein:

FIG. 1 illustrates an article comprising a trilaminate according to oneembodiment of the invention;

FIG. 2A illustrates a configuration of an outer fabric layer sealaccording to one embodiment of the invention;

FIG. 2B illustrates a configuration of an outer fabric layer sealaccording to one embodiment of the invention;

FIG. 2C illustrates another configuration of an outer fabric layer sealaccording to one embodiment of the invention;

FIG. 2D illustrates another configuration of an outer fabric layer sealaccording to one embodiment of the invention;

FIG. 2E illustrates a configuration of a laminate seal according to oneembodiment of the invention;

FIG. 2F illustrates a configuration of a laminate seal according to oneembodiment of the invention

FIG. 2G illustrates another configuration of a laminate seal accordingto one embodiment of the invention;

FIG. 2H illustrates another configuration of a laminate seal accordingto one embodiment of the invention

FIG. 3 illustrates a process flow diagram for making a barrier laminateaccording to an example embodiment of the invention;

FIGS. 4A-4C each illustrate individual steps in a method of making abarrier laminate according to an example embodiment of the invention;

FIGS. 5A-5C each illustrate individual steps, performed after stepsillustrated in FIGS. 4A-4C, in a method of making a barrier laminateaccording to an example embodiment of the invention;

FIG. 6A illustrates a step of inverting an intermediate barrier laminateformed in FIG. 5C; and

FIG. 6B illustrates the barrier laminate at the completion of theinverting step illustrated in FIG. 6A.

DETAILED DESCRIPTION

The invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the invention are shown. Indeed, this invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. As used in the specification, and in the appended claims,the singular forms “a”, “an”, “the”, include plural referents unless thecontext clearly dictates otherwise.

The invention includes articles, such as barrier laminates that may beprovided in a variety of geometric forms, that include an outer fabriclayer including an outer fabric layer seal formed between a first outerfabric layer side and a second outer fabric layer side to provide ahollow outer fabric layer structure defining an outer fabric layerconduit and a laminate, which may be at least partially encircled by theouter fabric layer and located within the hollow outer fabric layerstructure, including a barrier film layer and an inner fabric layer. Thelaminate may comprise a laminate seal, which is separate and distinctfrom the outer fabric layer seal, formed between a first laminate sideand a second laminate side to provide a hollow laminate structuredefining a laminate conduit. In accordance with certain embodiments ofthe invention, the laminate seal may be formed by directly bonding(e.g., thermally bonding) the barrier film layer to itself. The laminateseal, in according with such embodiments of the invention, comprises anonwoven-film-film-nonwoven structure by directly bonding (e.g.,thermally bonding) the barrier film layer of the laminate to itself. Alaminate seal having the nonwoven-film-film-nonwoven structureeliminates the presence of a fabric layer between the portions of thebarrier film layer bonded to each other to provide a laminate sealexhibiting improved liquid impermeability. In this regard, embodimentsof the present invention comprise articles (e.g., barrier laminates)including two separate and distinct seals to provide articles with seamsexhibiting improved seam barrier properties. For example, theconfiguration using two separate and distinct seals, as discussedherein, eliminate seam failure issues related to, at least, materialincompatibility issues between an outermost fabric layer and a corebarrier layer as realized by traditional articles formed from barrierlaminates (e.g., nonwoven-film-nonwoven barrier laminates). Inaccordance with certain embodiments of the invention, the barrier filmlayer may be located either directly or indirectly between the outerfabric layer and the inner fabric layer. For example, articles maycomprise a trilaminate including the barrier film layer directlyadjacent to and sandwiched between both the outer fabric layer and theinner fabric layer. In accordance with certain embodiments of theinvention, the articles may be devoid of bonds (e.g., mechanical bonds,adhesive bonds, thermal bonds, etc.) between the outer fabric layer andthe laminate. In this regard, for example, certain embodiments of theinvention form articles (e.g., barrier laminates in a sleeve or tubestructure) from, for example, two different and separate media (e.g.,outer fabric layer and laminate including a breathable liquid imperviousfilm and a nonwoven laminated together) that have been sealedindividually and combined into an article (e.g., barrier laminates in asleeve or tube structure).

Articles, according to certain embodiments of the invention, maycomprise a variety of shapes or forms and utilized in a variety ofend-use applications that may require liquid barrier properties. By wayof example only, articles according to certain embodiments of theinvention may be provided in the form of a surgical bodysuit, surgicalgown, surgical sleeves, etc. For example, the surgical gown market has aneed for surgical gowns with sleeve seams having both strength (e.g.,seam tensile strength) and liquid barrier properties (e.g., hydrostatichead, IPA penetration resistance, and ultimately F1670 (synthetic bloodbarrier test) /F1671 (viral barrier test) compliance). In this regard,certain embodiments of the invention, may comprise surgical gowns withsleeve seams having a sealing mechanism (e.g., two separate and discreteseams as disclosed herein) that provides surgical gowns/surgical sleeveswith AAMI 4-rated seams and/or seals. In this regard, certainembodiments of the invention address the simultaneous needs of seamstrength (e.g., seal strength at seams) and barrier propertiesassociated with a sealed seam by managing them separately (e.g., twoseparate and discrete seams as disclosed herein) to provide AAMI 4-ratedarticles (e.g., sleeves, pants, gowns, etc.). For instance, articlesaccording to certain embodiments of the invention may be devoid of bonds(e.g., mechanical bonds, adhesive bonds, thermal bonds, etc.) betweenthe outer fabric layer and the laminate. In accordance with certainembodiments of the invention, an article (e.g., a trilaminate includingthe barrier film layer sandwiched between both the outer fabric layerand the inner fabric layer) may be incorporated into a larger structureor attached to a separate and distinct second article (e.g., a bodyportion of a surgical gown). In this regard, articles according tocertain embodiments of the invention may comprise one or more bondsattaching the article to a separate and distinct second article (e.g., abody portion of a surgical gown). In such embodiments, for example, thearticle (e.g., a trilaminate including the barrier film layer sandwichedbetween both the outer fabric layer and the inner fabric layer) may bedevoid of bonds between the outer fabric layer and the laminate exceptfor the one or more bonds attaching the article to the separate anddistinct second article. In accordance with certain embodiments of theinvention, an overlapping area between the outer fabric layer and thelaminate may comprise an unbounded portion being devoid of bonds betweenthe outer fabric layer and the laminate. In accordance with certainembodiments of the invention, the unbounded portion may comprise fromabout 75% to about 100% of the overlapping area (e.g., from about 75% toabout 100% of the overlapping area may be devoid of bonds). Inaccordance with certain embodiments of the invention, the unboundedportion may comprise from at least about any of the following: 75, 80,85, 90, and 95% of the overlapping area and/or at most about 100, 99,98, 97, 96, and 95% of the overlapping area (e.g., about 90 to about100%, about 95% to about 98%, etc.). In accordance with certainembodiments of the invention, the unbounded portion may be locatedbetween two separate and distinct bonded portions. For example, the twoseparate and distinct bonded portions may be located at or near the endsof the article and may be provided to attach the article to a separateand distinct second article, such as a body portion of a surgical gownand/or a cuff. By way of example only, a first bonded portion may beprovided to attach a first end of the article to a body portion of asurgical gown and a second bonded portion may be provided to attach orform a cuff at the opposite end of the article.

The terms “substantial” or “substantially” may encompass the wholeamount as specified, according to certain embodiments of the invention,or largely but not the whole amount specified according to otherembodiments of the invention.

The terms “polymer” or “polymeric”, as used interchangeably herein, maycomprise homopolymers, copolymers, such as, for example, block, graft,random, and alternating copolymers, terpolymers, etc., and blends andmodifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” or “polymeric” shall include all possiblestructural isomers; stereoisomers including, without limitation,geometric isomers, optical isomers or enantionmers; and/or any chiralmolecular configuration of such polymer or polymeric material. Theseconfigurations include, but are not limited to, isotactic, syndiotactic,and atactic configurations of such polymer or polymeric material. Theterm “polymer” or “polymeric” shall also include polymers made fromvarious catalyst systems including, without limitation, theZiegler-Natta catalyst system and the metallocene/single-site catalystsystem. The term “polymer” or “polymeric” shall also include, inaccording to certain embodiments of the invention, polymers produced byfermentation process or biosourced.

The terms “nonwoven” and “nonwoven web”, as used herein, may comprise aweb having a structure of individual fibers, filaments, and/or threadsthat are interlaid but not in an identifiable repeating manner as in aknitted or woven fabric. Nonwoven fabrics or webs, according to certainembodiments of the invention, may be formed by any processconventionally known in the art such as, for example, meltblowingprocesses, spunbonding processes, hydroentangling, air-laid, and bondedcarded web processes.

The term “staple fiber”, as used herein, may comprise a cut fiber from afilament. In accordance with certain embodiments, any type of filamentmaterial may be used to form staple fibers. For example, staple fibersmay be formed from cellulosic fibers, polymeric fibers, and/orelastomeric fibers. Examples of materials may comprise cotton, rayon,wool, nylon, polypropylene, and polyethylene terephthalate. The averagelength of staple fibers may comprise, by way of example only, from about2 centimeter to about 15 centimeter.

The term “spunbond”, as used herein, may comprise fibers which areformed by extruding molten thermoplastic material as filaments from aplurality of fine, usually circular, capillaries of a spinneret with thediameter of the extruded filaments then being rapidly reduced. Accordingto an embodiment of the invention, spunbond fibers are generally nottacky when they are deposited onto a collecting surface and may begenerally continuous. It is noted that the spunbond used in certaincomposites of the invention may include a nonwoven described in theliterature as SPINLACE®.

The term “meltblown”, as used herein, may comprise fibers formed byextruding a molten thermoplastic material through a plurality of finedie capillaries as molten threads or filaments into converging highvelocity, usually hot, gas (e.g. air) streams which attenuate thefilaments of molten thermoplastic material to reduce their diameter,which may be to microfiber diameter, according to certain embodiments ofthe invention. According to an embodiment of the invention, the diecapillaries may be circular. Thereafter, the meltblown fibers arecarried by the high velocity gas stream and are deposited on acollecting surface to form a web of randomly disbursed meltblown fibers.Meltblown fibers are microfibers which may be continuous ordiscontinuous and are generally tacky when deposited onto a collectingsurface.

The term “hydroentangle” or “hydroentangled”, as used herein, maycomprise a process for bonding a nonwoven fabric by using high pressurewater jets to intermingle the fibers. Several rows of water jets aredirected against the fiber web, which is supported by a movable fabric.Fiber entanglements are introduced by the combined effects of the waterjets and the turbulent water created in the web, which intertwinesneighboring fibers.

The term “layer”, as used herein, may comprise a generally recognizablecombination of similar material types and/or functions existing in theX-Y plane.

As used herein, the term “proximate” in the context of the relativepositioning of two particular layers of a multilayer film may comprisethe positioning of a layer being one or more layers removed from anotherlayer. For example, the term “proximate” in the context of the relativepositioning of a first layer and a second layer may mean that the firstand second layers may be separated by 1, 2, 3, or more intermediatelayers, such as layers positioned between the core layer and a skinlayer. Layers that are positioned proximate to one another areadequately positioned so as to achieve a desired construct and/orfunctionality.

The term “bicomponent fibers”, as used herein, may comprise fibersformed from at least two different polymers extruded from separateextruders but spun together to form one fiber. Bicomponent fibers arealso sometimes referred to as conjugate fibers or multicomponent fibers.The polymers are arranged in a substantially constant position indistinct zones across the cross-section of the bicomponent fibers andextend continuously along the length of the bicomponent fibers. Theconfiguration of such a bicomponent fiber may be, for example, asheath/core arrangement wherein one polymer is surrounded by another, ormay be a side-by-side arrangement, a pie arrangement, or an“islands-in-the-sea” arrangement, each as is known in the art ofmulticomponent, including bicomponent, fibers. The “bicomponent fibers”may be thermoplastic fibers that comprise a core fiber made from onepolymer that is encased within a thermoplastic sheath made from adifferent polymer or have a side-by-side arrangement of differentthermoplastic fibers. The first polymer often melts at a different,typically lower, temperature than the second polymer. In the sheath/corearrangement, these bicomponent fibers provide thermal bonding due tomelting of the sheath polymer, while retaining the desirable strengthcharacteristics of the core polymer. In the side-by-side arrangement,the fibers shrink and crimp creating z-direction expansion.

As used herein, the term “monolithic” film may comprise any film that iscontinuous and substantially free or free of pores (e.g., devoid ofpores). In certain alternative embodiments of the invention, a“monolithic” film may comprise fewer pore structures than wouldotherwise be found in a microporous film. According to certainnon-limiting exemplary embodiments of the invention, a monolithic filmmay act as a barrier to liquids and particulate matter but allow watervapor to pass through, such as by absorbing water vapor on one side ofthe film, transporting the water vapor through the film, and releasingthe water vapor on the opposite side of the film. In addition, withoutintending to be bound by theory, by achieving and maintaining highbreathability, it is possible to provide an article that is morecomfortable to wear because the migration of water vapor through thelaminate helps reduce and/or limit discomfort resulting from excessmoisture trapped against the skin. Monolithic films, according tocertain embodiments of the invention, may also act as barriers tobacteria and viruses and may provide an article or garment that reducesthe contamination of the surroundings and the spread of infections andillness caused by the bacteria and viruses,

The term “highly breathable polymer”, as used herein, may comprise anypolymer that is selectively permeable to water vapor but substantiallyimpermeable to liquid water and that can form a breathable film, forexample, in which the polymer is capable of absorbing and desorbingwater vapor and providing a barrier to aqueous fluids (e.g., water,blood, etc.). For example, a highly breathable polymer can absorb watervapor from one side of a film and release it to the other side of film,thereby allowing the water vapor to be transported through the film. Asthe highly breathable polymer can impart breathability to films, filmsformed from such polymers do not need to include pores (e.g., monolithicfilm). According to certain embodiments of the invention, “highlybreathable polymer” may comprise any thermoplastic polymer having a MVTRof at least 500 g/m²/day when formed into a film, such as a film having,for example, a thickness of about 25 microns or less. According tocertain embodiments of the invention, “highly breathable polymer” maycomprise any thermoplastic polymer having a MVTR of at least 750g/m²/day or of at least 1000 g/m²/day when formed into a film, such as afilm having, for example, a thickness of about 25 microns or less.According to certain embodiments of the invention, highly breathablepolymers may comprise, for example, any one or combination of apolyether block amide copolymer (e.g., PEBAX® from Arkema. Group),polyester block amide copolymer, copolyester thermoplastic elastomer(e.g., ARNITEL® from DSM Engineering Plastics, HYTREL® from E.I. DuPontde Nemours and Company), or thermoplastic urethane elastomer (TPU).

The term “non-breathable material”, as used herein, may comprise anymaterial that either does not allow water vapor to pass through thematerial or substantially impedes the movement of water vapor throughthe material. According to an embodiment of the invention,non-breathable materials may comprise a thermoplastic resin, such aspolyethylene, polypropylene, polyester, polyamide, polyethylene vinylacetate, polyvinyl chloride, or polyvinylidene chloride, or anycopolymers or physical blends thereof. In other embodiments of theinvention, the thermoplastic resin may comprise or even furthercomprise, for example, a low density polyethylene (LDPE), linear lowdensity polyethylene (LLDPE), high density polyethylene (HDPE),polypropylene (PP), copolymers or terpolymers of ethylene, orfunctionalized polymers of ethylene, or any coextrusion or blendthereof.

The term “laminate”, as used herein, may be a structure comprising twoor more layers, such as a film layer and a fibrous layer (e.g., a wovenor nonwoven fabric). The two layers of a laminate structure may bejoined together or releasably engaged to each other such that asubstantial portion of their common X-Y plane interface, according tocertain embodiments of the invention. In accordance with certainembodiments of the invention, two layers of a laminate structure may bereleaseably engaged to each other due, for example, to frictionalforces, relative sizing, and/or relative positioning of the two layers.

The term “seal”, as used herein, may comprise a thermal, adhesive, ormechanical bond formed in or with a material, for example, to provide aliquid impermeable seam including said seal. For example, a firstportion of a material (e.g., a film, a nonwoven, or laminate) may bepositioned over or adjacent to a second portion of the material andbonded together. In this regard, the seal may comprise, with respect tofabrics, the bringing together of at least a portion of the fibers offabric into closer proximity or attachment there-between (e.g., fusedtogether) to form a bonding site or bonding sites. The bonding site orbonding sites, for example, may comprise a discrete or localized regionof the material that has been softened or melted and optionallysubsequently or simultaneously compressed to form a discrete orlocalized deformation in the material. In accordance with certainembodiments of the invention, the formation of a “seal” may be achievedby methods that apply, for example, heat and/or pressure to the materialto be sealed (e.g., a film, a nonwoven, or laminate). One non-limitingmethod comprises thermal bonding. In accordance with certainembodiments, the “seal” may comprise a continuous bond formed, asopposed to a series of independent and discrete bond points, along agiven length of material to be sealed.

All whole number end points disclosed herein that can create a smallerrange within a given range disclosed herein are within the scope ofcertain embodiments of the invention. By way of example, a disclosure offrom about 10 to about 15 includes the disclosure of intermediateranges, for example, of: from about 10 to about 11; from about 10 toabout 12; from about 13 to about 15; from about 14 to about 15; etc.Moreover, all single decimal (e.g., numbers reported to the nearesttenth) end points that can create a smaller range within a given rangedisclosed herein are within the scope of certain embodiments of theinvention. By way of example, a disclosure of from about 1.5 to about2.0 includes the disclosure of intermediate ranges, for example, of:from about 1.5 to about 1.6; from about 1.5 to about 1.7; from about 1.7to about 1.8; etc.

I. Articles Exhibiting Barrier Properties

In one aspect, the invention provides articles (e.g., barrier laminatesin the form of surgical gowns, sleeves, surgical drapes, pant legs,etc.) comprising an outer fabric layer and a laminate comprising atleast a barrier film layer and an inner fabric layer, in which the outerfabric layer at least partially (e.g., completely or substantiallycompletely) encircles and overlies the laminate. In accordance withcertain embodiments of the invention, the laminate may comprise thebarrier film layer adhesively glued to the inner fabric layer, thermallylaminated to the inner fabric layer (e.g., ultrasonic bonds, pointbonded, etc.), or extrusion coated onto the inner fabric layer. Inaccordance with certain embodiments of the invention the barrier filmlayer may be located either directly or indirectly between the outerfabric layer and the inner fabric layer. For example, the outer fabriclayer may comprise a first side surface and a second side surface, inwhich the second side surface is located adjacent or proximate to thebarrier film layer. In accordance with certain embodiments of theinvention, for instance, articles may comprise a trilaminate includingthe barrier film layer directly adjacent to and sandwiched between boththe outer fabric layer and the inner fabric layer. In accordance withcertain embodiments of the invention, the barrier film layer maycomprise a monolithic film or a porous film (e.g., including severalmicro-pores formed therein). The barrier film layer, in accordance withcertain embodiments of the invention, may comprise a single layer filmor a multilayer film.

As illustrated in FIG. 1, the article 1 includes an outer fabric layer10 and a laminate 20 (e.g., a bilaminate) comprising a barrier filmlayer 21 and an inner fabric layer 22. As shown in FIG. 1, the outerfabric layer 10 encircles and overlies the laminate 20, in which thebarrier film layer 21 is positioned between the outer fabric layer 10and the inner fabric layer 22. The barrier film layer 21, as illustratedby the embodiment shown in FIG. 1, may be located directly between theouter fabric layer 10 and the inner fabric layer 22. In this regard, theouter fabric layer 10 comprises a first side surface 11 and a secondside surface 12, in which the second side surface 12 is located adjacentto the barrier film layer 21.

In accordance with certain embodiments of the invention, the articlesmay be devoid of bonds (e.g., mechanical bonds, adhesive bonds, thermalbonds, etc.) between the outer fabric layer and the laminate. The outerfabric layer and the laminate, according to certain embodiments of theinvention, may be held together (e.g., releasably together), forexample, via frictional forces between the outer fabric layer and thelaminate. The frictional forces between the outer fabric layer and thelaminate may be increased or decreased by modifying the relative sizing(e.g., respective length, diameter, etc.) of the outer fabric layer andthe laminate, and/or the relative positioning of the outer fabric layerand the laminate. In accordance with certain embodiments of theinvention, the second side surface of the outer fabric layer maycomprise a second surface coefficient of friction and the first sidesurface of the outer fabric layer comprises a first surface coefficientof friction, in which the second surface coefficient of friction isgreater than the first surface coefficient of friction. In this regard,the second side surface of the outer fabric layer may be our have beensubjected to a processing operation to render this side of the outerfabric layer more abrasive or capable of engaging the laminate toincrease the second surface coefficient of friction.

As noted above, the barrier film layer, in accordance with certainembodiments of the invention, may comprise a monolithic film or a porousfilm (e.g., including several micro-pores formed therein). In accordancewith certain embodiments of the invention, the barrier film layer may bemade, at least in part, from polymers that are permeable to water vaporwhile being impermeable to aqueous liquids. In accordance with certainembodiments of the invention, for instance, the barrier film layer maycomprise a monolithic film including at least one highly breathablepolymer. According to certain embodiments of the invention, the highlybreathable polymer may be hygroscopic. In certain embodiments of theinvention, the barrier film layer (e.g., monolithic film) may compriseat least about 50 wt. % to about 100 wt. % (e.g., at least about 75 wt.% to about 100 wt. %) of a highly breathable polymer. As such, incertain embodiments, barrier film layer may comprise a monolithic filmincluding at least one highly breathable polymer comprising from atleast about any of the following: 50, 75, 80, and 100 wt. % (e.g., atleast about 50 wt. % to about 100 wt. %).

In such embodiments, the highly breathable polymer may comprise at leastone of a thermoplastic urethane (TPU), a polyether block amide copolymer(e.g., PEBAX® from Arkema Group or Vetsamid® E from Evonik), or acopolyester thermoplastic elastomer (e.g., ARNITEL® from DSM EngineeringPlastics, HYTREL® from E.I. DuPont de Nemours and Company). In certainembodiments, for example, the highly breathable polymer may comprise acopolyester thermoplastic elastomer. In this regard, certain embodimentsof the invention may comprise a monolithic barrier film layer comprisingat least one highly breathable polymer.

In accordance with certain embodiments of the invention, the barrierfilm layer may optionally also comprise at least one non-breathablepolymer. In some embodiments, for instance, the barrier film layer maycomprise at most about 0 wt. % to at most about 50 wt. % of thenon-breathable polymer. As such, in certain embodiments, the barrierfilm layer may comprise a non-breathable polymer comprising from at mostabout any of the following: 50, 40, 25, 20, 15, 10, 5 and 0 wt. % (e.g.,at most about 0 wt. % to about 50 wt. %).

In accordance with certain embodiments of the invention, the barrierfilm layer may comprise a microporous film that comprises a porestructure configured to pass F1670 (synthetic blood barrier test) andF1671 (viral barrier test) testing. As noted previously, the barrierfilm layer may comprise a multilayer film including one or moreindividual monolithic film layers and one or more individual microporousfilm layers. For example, such a multilayer film may comprise an AB,ABA, ABABA structure (where ‘A’ represents an individual microporousfilm layer and ‘B’ represents an individual monolithic film layer, orvice versa), or the like, as long as the resulting multilayer film isbreathable to moisture vapor and impervious to liquid, while alsopassing F1670 (synthetic blood barrier test) and F1671 (viral barriertest) testing.

In accordance with certain embodiments of the invention, the laminatemay comprise a barrier film layer that optionally includes protrusions,such as small protrusions from particulate fillers incorporated into thebarrier film layer, that engage the second side surface of the outerfabric layer to further increase the frictional forces between the outerfabric layer and the laminate. The barrier film layer, in accordancewith certain embodiments of the invention, may comprise a multi-layerbarrier film including a first outer film layer (e.g., a skin layer)comprising the plurality of protrusions formed by discrete fillerparticulates incorporated therein. In certain embodiments of theinvention including such a multi-layer barrier film, the first outerfilm layer may be the only individual layer of the multi-layer barrierfilm including particulates therein. For example, the multi-layerbarrier film may include a second layer comprising a highly breathablepolymer forming a monolithic film layer, which is devoid of anyparticulates. In this regard, the monolithic film layer may provide thedesired barrier properties as well as water vapor breathability whilethe first outer film layer (e.g., skin layer) simply provides increasedfrictional forces between the laminate and the outer fabric layer. Inaccordance with certain embodiments of the invention, the protrusionsformed by discrete filler particulates, in which the filler particulatesmay comprise particulate inorganic materials such as, for example,calcium carbonate, various kinds of clay, silica, alumina, bariumsulfate, sodium carbonate, talc, magnesium sulfate, titanium dioxide,zeolites, aluminum sulfate, cellulose-type powders, diatomaceous earth,magnesium sulfate, magnesium carbonate, barium carbonate, kaolin, mica,carbon, calcium oxide, magnesium oxide, aluminum hydroxide, glassparticles, and the like. In this regard, the filler particulates maydefine the plurality of protrusions extending outwardly from the barrierlayer film (e.g., a skin layer of a multi-layer barrier film).

In accordance with certain embodiments of the invention, the outerfabric layer comprises a nonowen fabric or a woven fabric. In accordancewith certain embodiments of the invention, the outer fabric layer maynaturally or otherwise rendered hydrophobic by one or more additives. Inthis regard, the outer fabric layer may be or rendered non-absorbent(e.g., repels or at least does not attract polar liquids such as water).In accordance with certain embodiments of the invention, for example,the outer fabric layer may be water and alcohol repellent. The innerfabric layer, according to certain embodiments of the invention, maycomprise a nonowen fabric or a woven fabric, which may be eitherhydrophobic or hydrophilic. In accordance with certain embodiments ofthe invention, both the outer fabric layer and the inner fabric layercomprise a nonwoven fabric. Each of the outer fabric layer and the innerfabric layer may independently include continuous fibers, staple fibers,or both. The nonwoven fabric of the outer fabric layer and/or the innerfabric layer may comprise one or more individual nonwoven web layers. Inthis regard, the nonwoven fabric of the outer fabric layer and/or theinner fabric layer may comprise spunbond nonwovens, meltblown nonwovens,hydroentangled nonwovens, air-laid nonwovens, bonded carded nonwovens,or any combination thereof. For example, the outer fabric layer and/orthe inner fabric layer may comprise a spunbond nonwoven or aspunbond-meltblown-spunbond (SMS) nonwoven. In accordance with certainembodiments of the invention, the outer fabric layer and/or the innerfabric layer may comprise one or more polymeric materials. For example,the nonwoven fabric of the outer fabric layer and/or the inner fabriclayer may comprise filaments comprising a polypropylene, polyethylene,or both. In certain embodiments of the invention, for instance, thepolymeric material may comprise high density polypropylene or highdensity polyethylene, low density polypropylene or low densitypolyethylene, linear low density polypropylene or linear low densitypolyethylene, a copolymer of polypropylene or ethylene, and anycombination thereof. In certain embodiments of the invention, forinstance, the polymeric material may comprise polypropylene of one ormore different forms, such as a homopolymer, a random copolymer, apolypropylene made with a Ziegler-Natta or metallocene or other catalystsystem. The polypropylene may be provided in a variety of configurationsincluding isotactic, syndiotactic, and atactic configurations ofpolypropylene. In some embodiments of the invention, the polymericmaterial may comprise at least one of a polypropylene, a polyethylene, apolyester, a polyamide, or combinations thereof. In accordance withcertain embodiments of the invention, the polymeric material maycomprise a biopolymer (e.g., polylactic acid (PLA),poiyhydroxyalkanoates (PHA) and poly(hydroxycarboxylic) acids). Inaccordance with certain embodiments of the invention, the nonwovenfabric of the outer fabric layer and/or the inner fabric layer maycomprise multi-component fibers, such as bicomponent fibers having asheath-core configuration. For example, certain embodiments of theinvention may comprise bicomponent fibers comprising a sheathcomprising, by way of example only, a polyethylene or a propylene and acore comprising, by way of example only, at least one of apolypropylene, a polyethylene, a polyester, or a biopolymer (e.g.,polylactic acid (PLA) polyhydroxyalkanoates (PHA), andpoly(hydroxycarboxylic) acids. The outer fabric layer and/or the innerfabric layer my comprise filaments or fibers comprising a roundcross-section, non-round cross section (e.g., ribbon shaped, trilobalshaped, etc.), or combinations thereof. In accordance with certainembodiments of the invention, the outer fabric layer and/or the innerfabric layer may be untreated or treated with one or more additives,such as a repellent and an antistatic finish.

In accordance with certain embodiments of the invention, the outerfabric layer and/or the inner fabric layer my comprise a repellentcomposition disposed thereon. In accordance with certain embodiment ofthe invention, the repellent composition may be disposed and/or appliedvia topical and/or internal treatment of the fiber(s) of the outerfabric layer and/or the inner fabric layer. For example, the repellentcomposition may comprise a material or materials that repel a liquid,such as water and/or blood. In this regard, the repellent compositionmay comprise a hydrophobic additive. In accordance with certainembodiments of the invention, the repellent composition may be providedat an amount sufficient to exhibit at least the necessary level ofalcohol repellency for surgical applications. In this regard, the outerfabric layer and/or the inner fabric layer may comprise a topicallytreated fabric comprising a desired alcohol repellency. In accordancewith certain embodiments, the repellent composition may comprise atleast one fluorochemical. For example, the at least one fluorochemicalmay comprise at least one of a C4 fluorochemical, a C6 fluorochemical, aC8 fluorochemical, a C10 fluorochemical, or any combination thereof.

The outer fabric layer, in accordance with certain embodiments of theinvention, may comprise an outer fabric layer seal (e.g., the outerfabric layer being sealed to itself at an outer fabric layer seam)formed between a first outer fabric layer side and a second outer fabriclayer side to provide a hollow outer fabric layer structure defining anouter fabric layer conduit. The outer fabric layer seal may comprise aheat or thermal seal, adhesive seal, ultrasonic seal, mechanical seal,or any combinations thereof. The laminate, in accordance with certainembodiments of the invention, may comprise a laminate seal (e.g., thelaminate being sealed to itself at a laminate seam), which is separateand distinct from the outer fabric layer seal, formed between a firstlaminate side and a second laminate side to define a hollow laminatestructure defining a laminate conduit. In accordance with certainembodiments of the invention, the laminate seal may comprise a coredefined by the barrier film layer of, for example, the first laminateside being melted and fused to the barrier film layer of, for example,the second laminate side. In this regard, the fibers of the inner fabriclayer of the laminate melt and fuse to the core of the laminate seal.The laminate seal may comprise a heat or thermal seal, adhesive seal,ultrasonic seal, mechanical seal, or any combinations thereof. In thisregard, certain embodiments of the invention may comprise two separateand distinct seals, while the outer fabric layer and the laminate (e.g.,bilaminate encircled by the outer fabric layer) are not bonded to eachother (e.g., devoid of bonds therebetween).

As shown, for example, in FIGS. 2A-2D, the outer fabric layer seal 13may be located and/or formed between a first outer fabric layer side 14and a second outer fabric layer side 15. FIGS. 2B and 2D illustrateembodiments in which the outer fabric layer seal 13 comprises alocalized discrete or localized deformation region, for example, via thesoftening and/or melting and compression to form the discrete orlocalized deformation. FIG. 4A provides a better illustration of thepre-bonding/pre-sealing orientation of the first outer fabric layer side14 and the second outer fabric layer side 15. FIGS. 2A-2D illustrateembodiments in which the outer fabric layer is bonded to itself at theouter fabric layer seal 13. As shown in FIGS. 2A and 2B, a firstside-surface of the first outer fabric layer side 14 may be bonded to asecond side-surface (being opposite of the first side-surface) of thesecond outer fabric layer side 15. As shown in FIGS. 2C and 2D, a firstside-surface of the first outer fabric layer side 14 may be bonded tothe same side-surface of the second outer fabric layer side 15. FIGS.2E-2H show that the laminate seal 23 may be located and/or formedbetween a first laminate side 24 and a second laminate side 25. FIGS.2E-2H illustrate embodiments in which the laminate is bonded to itselfat the laminate seal 23. FIGS. 2F and 2H illustrate embodiments in whichthe laminate seal 13 comprises a localized discrete or localizeddeformation region, for example, via the softening and/or melting andcompression to form the discrete or localized deformation. As shown inFIGS. 2E and 2F, a first side-surface of the first laminate side 24 maybe bonded to a second side-surface (being opposite of the firstside-surface) of the second laminate side 25 (e.g., afilm-nonwoven-nonwoven-film seal structure). As shown in FIGS. 2G and2H, a first side-surface of the first laminate side 24 may be bonded tothe same side-surface of the second laminate side 25. As illustrated inFIGS. 2G and 2H, for example, the laminate seal 13 may be formed bydirectly bonding (e.g., thermally bonding) the barrier film layer of thelaminate to itself (e.g., same side-surface of the laminate). Thelaminate seal, in according with such embodiments of the invention,comprises a nonwoven-film-film-nonwoven structure by directly bonding(e.g., thermally bonding) the barrier film layer of the laminate toitself. A laminate seal having the nonwoven-film-film-nonwoven structureeliminates the presence of a fabric layer between the portions of thebarrier film layer bonded to each other to provide a laminate sealexhibiting improved liquid impermeability. FIG. 5A provides a betterillustration of the pre-bonding/pre-sealing orientation of the firstlaminate side 24 and the second laminate side 25. Although FIGS. 2A-2Hillustrate a cross-sectional view of seals 13, 23, it should beunderstood that the seals 13, 23, in according to certain embodiments ofthe invention, may extend continuously along the length (e.g., in and/orout of the plane of the paper) of the respective material (e.g., outerfabric layer 10 and laminate 20). The outer fabric layer seal 13,according to certain embodiments of the invention, may not be continuousbut instead comprise one or more discrete bond locations.

As shown in FIG. 1, the sealing (e.g., bonding via outer fabric layerseal 13) provides a hollow outer fabric layer structure defining anouter fabric layer conduit 16 extending from a first outer fabric layerend 17 (as best shown in FIG. 4A) to a second outer fabric layer end 18(as best shown in FIG. 4A). Although not shown in FIG. 1, the outerfabric layer seal 13 may extend continuously from the first outer fabriclayer end 17 to the second outer fabric layer end 18. In this regard,the first outer fabric layer end 17 defines a first opening 32 and thesecond outer fabric layer end defines a second opening 34. In theembodiment illustrated in FIG. 1, the first opening 32 may be largerthan the second opening 34. The hollow outer fabric layer structure maycomprise a variety of configurations, such as a cylindricalconfiguration, a truncated cone configuration, or a truncated triangularconfiguration.

As shown in FIG. 1, the sealing (e.g., bonding via outer fabric layerseal 23) provides a hollow laminate structure defining a laminateconduit extending from a first laminate end 27 (as best shown in FIG.5A) to a second laminate end 28 (as best shown in FIG. 5A). Although notshown in FIG. 1, the laminate seal 23 may extend continuously from thefirst laminate end 27 to the second laminate end 28. In this regard, thefirst laminate end 27 defines a first laminate opening 36 and the secondlaminate end defines a second laminate opening 38. The embodimentillustrated in FIG. 1, the first laminate opening 36 may be larger thanthe second laminate opening 38. The hollow laminate structure maycomprise a variety of configurations, such as a cylindricalconfiguration, a truncated cone configuration, or a truncated triangularconfiguration. As shown in FIG. 1, the barrier film layer 21 is locatedbetween the outer fabric layer 10 and the inner fabric layer 22. As alsoshown in FIG. 1, the hollow outer fabric layer structure and the hollowlaminate structure may be concentrically located with respect to eachother.

In accordance with certain embodiments of the invention, the outerfabric layer 10 comprises a non-sealed geometric shape, such as shown inFIG. 4A. The outer fabric layer 10 also comprises a non-sealed outerfabric layer length from the first outer fabric layer end 17 and thesecond outer fabric layer end 18 and a non-sealed outer fabric layerwidth from the first outer fabric layer side 14 the second outer fabriclayer side 15, such as shown in FIG. 4A. Similarly, the laminate 10comprises a non-sealed laminate geometric shape, such as shown in FIG.5A. The laminate 10 also comprises a non-sealed laminate length from thefirst laminate end 27 and the second laminate end 28 and a non-sealedlaminate width from the first laminate side 24 the second laminate side25, such as shown in FIG. 5A. As illustrated by FIGS. 4A and 5A, thenon-sealed geometric shape and the non-sealed laminate geometric shapeare the same or substantially the same. In accordance with certainembodiments of the invention, the outer fabric layer 10 includes anouter fabric layer 2D surface area is the same or different than alaminate 2D surface area. In accordance with certain embodiments of theinvention, the outer fabric layer 2D surface area is less than thelaminate 2D surface area. The non-sealed outer fabric layer length,according to certain embodiments of the invention, may comprise the same(or substantially the same) as the non-sealed laminate length.

As illustrated by FIG. 4A, the non-sealed outer fabric layer widthvaries according to a defined profile from a first outer fabric layerwidth W1 (FIG. 4A) to a second outer fabric layer width W2 (FIG. 4A)along the non-sealed outer fabric length. The non-sealed laminate widthalso varies according to the defined profile from a first laminate widthWL1 (FIG. 5A) to a second laminate width WL2 (FIG. 5A) along thenon-sealed laminate length. In accordance with certain embodiments ofthe invention, the non-sealed outer fabric layer width is the same orsmaller than the non-sealed laminate width along corresponding pointsalong an article length. In this regard, the non-sealed outer fabriclayer width may comprise at least about 0.1 mm shorter than thenon-sealed laminate width in at least one corresponding point along anarticle length (or the entire length of the article). In accordance withcertain embodiments of the invention, the non-sealed outer fabric layerwidth may comprise from at least about any of the following: 0.1, 0.5,1, 1.5, 2.0, 5 and 10 mm shorter than the non-sealed laminate width inat least one corresponding point along an article length (or the entirelength of the article) and/or at most about 20, 15, 10, and 5% mmshorter than the non-sealed laminate width in at least one correspondingpoint along an article length (or the entire length of the article)(e.g., about 0.5 -10 mm, about 1 to about 2 mm).

In accordance with certain embodiments of the invention, the outerfabric layer seal comprises an outer fabric layer seal elongation andthe laminate seal comprises a laminate seal elongation, in which theouter fabric layer seal elongation is equal to or less than the laminateseal elongation when subjected to the same tensile force. In certainembodiments, for example, the outer fabric layer seal elongation is fromabout 1 to about 15% (e.g., about 5 to about 10%) less than the laminateseal elongation. In accordance with certain embodiments of theinvention, the outer fabric layer seal elongation may comprise from atleast about any of the following: 1, 2, 3, 4, 5, and 10% less than thelaminate seal elongation and/or at most about 20, 15, 10, and 5% lessthan the laminate seal elongation (e.g., about 5 to about 10%, about 3to about 20%, etc.).

In accordance with certain embodiments of the invention, the outerfabric layer seal comprises an outer fabric layer seal tensile strengthfrom about 5 to about 25% (e.g., from about 10 to about 25%) strongerthan a laminate seal tensile strength. In accordance with certainembodiments of the invention, the outer fabric layer comprises an outerfabric layer seal tensile strength from at least about any of thefollowing: 5, 8, 10, 12, 15, 18, and 20% greater than a laminate sealtensile strength and/or at most about 30, 25, 20, and 15% greater than alaminate seal tensile strength (e.g., about 10 to about 25%, about 15 toabout 25%, etc.).

In accordance with certain embodiments of the invention, the hollowouter fabric layer structure (e.g., a sleeve or tube structure) maycomprise a hollow outer fabric layer perimeter and the hollow laminatestructure (e.g., a sleeve or tube structure) may comprise a hollowlaminate perimeter, in which the hollow outer fabric layer perimeter isequal to or smaller than the hollow laminate perimeter when both are ina relaxed and/or non-stretched state. For example, the hollow outerfabric layer perimeter may comprise from at least about any of thefollowing: 0.1, 0.5, 1, 1.5, 2.0, 5 and 10 mm shorter than the hollowlaminate perimeter in at least one corresponding point along the articlelength (or the entire length of the article) in a relaxed and/ornon-stretched state and/or at most about 20, 15, 10, and 5% mm shorterthan the hollow laminate perimeter in at least one corresponding pointalong an article length in a relaxed and/or non-stretched state (or theentire length of the article) (e.g., about 0.5-10 mm, about 1 to about 2mm). As noted above, the outer fabric layer seal (formed from bonding afabric layer to itself) may comprise a stronger seal, as evident by alarger tensile strength, than the laminate seal. By having the hollowouter fabric layer perimeter smaller than the hollow laminate perimeter,according to certain embodiments of the invention, an initial loadapplied to the article (e.g., such as a force exerted by a user'sbending elbow exerting force on the article) will be handled by thestronger outer fabric layer seal (e.g., the outer fabric layer sealtensile strength comprising a value greater than the laminate sealtensile strength as discussed above).

In accordance with certain embodiments of the invention, articles (e.g.,a trilaminate) may comprise a basis weight from about 25 to about 85grams-per-square-meter (gsm). Articles, in accordance with certainembodiments of the invention, may comprise a basis weight from at leastabout any of the following: 25, 30, 35, 40, 45, and 50 gsm and/or atmost about 100, 85, 80, 75, 70, 65, 60, 55, and 50 gsm (e.g., about 35to about 80 gsm, about 50 to about 80 gsm, etc.). The barrier filmlayer, in accordance with certain embodiments of the invention, maycomprise from about 5 to about 50% by weight of the article (e.g., atrilaminate). In accordance with certain embodiments of the invention,barrier film layer may comprise from at least about any of thefollowing: 5, 8, 10, 12, 15, 20, and 25% by weight of the article and/orat most about 50, 45, 40, 35, 30, and 25% by weight of the article(e.g., about 10 to about 30% by weight of the article, about 20 to about25% by weight of the article, etc.).

In accordance with certain embodiments of the invention, the articlescomprise barrier laminates (e.g., liquid barrier protection while alsoproviding breathability) in the form of surgical gowns, sleeves,surgical drapes, pant legs, a shoe cover, a head-piece, or facemask.

In this regard, the articles in accordance with certain embodiments ofthe invention may provide a user the perception of a softer feel incomparison to traditional articles suitable for AAMI 4-rated barrierlaminates. While not wishing to be bound by the following theory, itbelieved that the increased perception of softness by a user (e.g., awearer) may be attributed to one or more of the following: notably lessglue (or devoid of glue) present between the individual layers of thearticles, and the increased range of motion of the outer fabric layerand the laminate relative to each other (e.g., except where sewn orbonded onto the body of a gown or a cuff, the outer fabric layer and thelaminate may be generally free to slide past each other). In thisregard, articles according to certain embodiments of the invention bendmore freely than traditional articles suitable for AAMI 4-rated barrierlaminates. This increased level in ease of bending realized by a usermay translate into an increased perception of softness as well asproviding an overall more comfortable structure for wearing by a user.

II. Methods of Producing a Nonwoven Fabric

In yet another aspect, the invention provides a method of making barrierlaminates (and articles comprising such barrier laminates). Methods, inaccordance with certain embodiments of the invention and as shown inFIG. 3, comprise a step of providing an outer fabric layer, in which theouter fabric layer includes a first outer fabric layer side, a secondouter fabric layer side, a first outer fabric layer end, and a secondouter fabric layer end at operation 110. The methods may also comprise astep of forming a hollow outer fabric layer structure comprising anouter fabric layer conduit by bonding the first outer fabric layer sideto the second outer fabric layer side to form an outer fabric layer sealextending from the first outer fabric layer end to the second outerfabric layer end at operation 120. The methods may also comprise a stepof providing a laminate including a barrier film layer and an innerfabric layer, in which the laminate includes a first laminate side, asecond laminate side, a first laminate end, and a second laminate end atoperation 130. In accordance with certain embodiments of the invention,the methods may comprise encircling the hollow outer fabric layerstructure with the laminate, in which the barrier layer film is locatedeither directly or indirectly between the outer fabric layer and theinner fabric layer at operation 140. The methods may also comprise astep of forming a hollow laminate structure comprising a laminateconduit by bonding the first laminate side to the second laminate sideto form a laminate seal extending from the first laminate end to thesecond laminate end to form an intermediate barrier laminate, in whichthe hollow laminate structure encircles (e.g., concentrically encircles)the hollow outer fabric layer structure at operation 150. In thisregard, certain embodiments of the invention may comprise separatelyforming the hollow outer fabric layer structure (e.g., a sleeve or tubestructure) and the hollow laminate structure (e.g., a sleeve or tubestructure) followed by inserting the hollow outer fabric layer structureinside the hollow laminate structure such that the hollow outer fabriclayer structure is encircled by the hollow laminate structure to formthe intermediate barrier laminate. Methods, in accordance with certainembodiments of the invention, may comprise a step of inverting theintermediate barrier laminate (e.g., turning the intermediate barrierlaminate inside-out) to form the barrier laminate, in which the outerfabric layer encircles the laminate at the completion of the invertingstep at operation 160. In accordance with certain embodiments of theinvention, the inverting step hides the outer fabric layer seal on theinside of the assembled barrier laminate.

In accordance with certain embodiments of the invention, the step ofinverting the intermediate barrier laminate to form the barrier laminatecomprises pulling the second outer fabric layer end and the secondlaminate end through the outer fabric layer conduit and through thefirst laminate end or pulling the first outer fabric layer end and thefirst laminate end through the outer fabric layer conduit and throughthe second laminate end. In this regard, methods according to certainembodiments of the invention comprise turning the intermediate barrierlaminate inside-out such that the outer fabric layer overlies andencircles, at least a portion, of the laminate with the film barrierlayer being located directly or indirectly between the outer fabriclayer and the inner fabric layer.

Methods according to certain embodiments of the invention may be devoidof any active or passive steps of forming bonds (e.g., physical,adhesive, thermal) between the outer fabric layer and the laminate. Inthis regard, articles (e.g., barrier laminates) formed according tocertain embodiments of the invention may be devoid of bonds between theouter fabric layer and the laminate. In this regard, the outer fabriclayer and the laminate may be releasably engaged or attached to eachother due to frictional forces between the two materials as discussedpreviously.

As discussed previously, the barrier film may comprise a monolithic filmor a porous film and the outer fabric layer, as well as the inner fabriclayer, may comprise a woven or nonwoven. In certain embodiments of theinvention, the resulting barrier laminate comprises a trilaminateincluding a nonwoven outer fabric layer, a monolithic barrier filmlayer, and a nonwoven inner fabric layer.

In accordance with certain embodiments of the invention, the step ofbonding the first outer fabric layer side to the second outer fabriclayer side to form the outer fabric layer seal may comprise performing athermal bonding operation, an adhesive bonding operation, an ultrasonicbonding operation, a mechanical bonding, or any combinations thereof.The step of bonding the first laminate side to the second laminate sideto form the laminate seal may comprise performing a thermal bondingoperation, an adhesive bonding operation, an ultrasonic bondingoperation, a mechanical bonding, or any combinations thereof. Inaccordance with certain embodiments of the invention, the laminate sealmay be formed by directly bonding (e.g., thermally bonding) the barrierfilm layer to itself. The laminate seal, in according with suchembodiments of the invention, comprises a nonwoven-film-film-nonwovenstructure by directly bonding (e.g., thermally bonding) the barrier filmlayer of the laminate to itself. A laminate seal having thenonwoven-film-film-nonwoven structure eliminates the presence of afabric layer between the portions of the barrier film layer bonded toeach other to provide a laminate seal exhibiting improved liquidimpermeability. In accordance with certain embodiments, the step ofbonding the first laminate side to the second laminate side to form thelaminate seal comprises performing a thermal bonding operation (e.g.,heat sealing). In accordance with certain embodiments of the invention,for example, the outer fabric layer seal and/or the laminate seal may beindependently formed by thermal impulse sealing (e.g., the material tobe seamed together via seal formation are captured between sealingelements that apply heat and pressure), ultrasonic sealing, extrusion ofa hot melt (or other adhesive) between the two surfaces of the materialto be bonded together followed by a pressure mechanism that press bothsurfaces of the material against the hot melt.

FIGS. 4A-4C each illustrate individual steps in a method of making abarrier laminate according to an example embodiment of the invention.FIG. 4A, for instance, illustrates the cutting of an outer fabric layer10 into a outer fabric layer geometric shape including a first outerfabric layer side 14, a second outer fabric layer side 15, a first outerfabric layer end 17, and a second outer fabric layer end 18. FIG. 4Aincludes a dashed line illustrating a centerline through the length ofthe outer fabric layer. The geometric shape of the outer fabric layerincludes a first outer fabric layer end 17 that is greater than thesecond outer fabric layer end 18. That is, the width of the first outerfabric layer end W1 is greater than the width of the second outer fabriclayer end W2. Although FIG. 4A illustrates the first outer fabric layerend 17 being greater than the second outer fabric layer end 18 (e.g., W1being greater than W2), certain embodiments according to the inventionmay comprise the first outer fabric layer end 17 being equal to thesecond outer fabric layer end 18 (e.g., W1 being equal to W2). FIG. 4Billustrates an embodiment in which the outer fabric layer 10 from FIG.4A is folded in half and onto itself. Subsequently, the outer fabriclayer 10 can be sealed (e.g., bonded to form outer fabric layer seal 13)as shown in FIG. 4C. The outer fabric layer seal 13, as shown in FIG.4C, extends along the entire length of the outer fabric layer (e.g.,from the first outer fabric layer end 17 to the second outer fabriclayer end 18). The outer fabric seal 13, according to certainembodiments, may comprise one or more discrete bond points along aportion or the entirety of the length of the outer fabric layer orinstead a continuous bonded seal.

FIGS. 5A-5C each illustrate individual steps, performed (for example)after steps illustrated in FIGS. 4A-4C, in a method of making a barrierlaminate according to an example embodiment of the invention. Forexample, FIG. 5A illustrates the cutting of a laminate 20 into alaminate geometric shape including a first laminate side 24, a secondlaminate side 25, a first laminate end 27, and a second outer fabriclayer end 28. FIG. 5A includes a dashed line illustrating a centerlinethrough the length of the laminate 20. The geometric shape of thelaminate 20 is the same (or substantially the same) as the outer fabriclayer geometric shape of the outer fabric layer 10. In accordance withcertain embodiments of the invention, the method may also include a stepof placing the outer fabric layer 10 on top of the laminate 20 andaligning the first outer fabric layer end with the first laminate end,the second outer fabric layer end with the second laminate end, or both.The laminate geometric shape of the laminate includes a first laminateend 27 that is greater than the second laminate end 28. That is, thewidth of the first laminate end WL1 is greater than the width of thesecond laminate end WL2. Although FIG. 5A illustrates the first laminateend 27 being greater than the second laminate end 28 (e.g., WL1 beinggreater than WL2), certain embodiments according to the invention maycomprise the first laminate end 27 being equal to the second laminateend 28 (e.g., WL1 being equal to WL2). Although the geometric shapes ofthe outer fabric layer 10 and the laminate 20 may be the same (orsubstantially similar), W1 may be slightly larger than WL1 and/or W2 maybe slightly larger than WL2, as discussed herein. FIG. 5A alsoillustrates the positioning of the outer fabric layer 10 in a folded andsealed state positioned over the top of an upper-half portion of thenon-sealed laminate 20. In certain embodiments, the portion of the outerfabric layer 10 including the outer fabric layer seal 13 may be bentover and placed on top of laminate 20 (in a non-sealed state), in whichbending over the portion of the outer fabric layer 10 including theouter fabric layer seal 13 may be performed to prevent it from beingcaught in the subsequently formed laminate seal 23, according to thisparticular example embodiment. FIG. 5B illustrates an embodiment inwhich the laminate 20 is folded in half and onto itself, whileencircling the outer fabric layer 10. Subsequently, the laminate 20 canbe sealed (e.g., bonded to form laminate seal 23) as shown in FIG. 5C.The laminate seal 23, as shown in FIG. 5C, comprises a continuous sealthat extends continuously along the entire length of the outer fabriclayer (e.g., from the first laminate end 27 to the second laminate end28). As shown in FIG. 5C, the outer fabric layer is completely encircledby the laminate 10 to form an intermediate barrier laminate 50.

FIG. 6A illustrates a step of inverting the intermediate barrierlaminate 50 formed in FIG. 5C. In this regard, the step of inverting theintermediate barrier laminate 50 comprises turning the intermediatebarrier laminate 50 inside-out to form the barrier laminate 1, in whichthe outer fabric layer 10 encircles the laminate 20 at the completion ofthe inverting step such that the inner fabric layer comprises the innermost side of the barrier laminate 1 and the outer fabric layer 10 is theoutermost side of the barrier laminate 1 as shown in FIG. 6B. Inaccordance with certain embodiments of the invention, the step ofinverting the intermediate barrier laminate 50 to form the barrierlaminate 1 comprises pulling the second outer fabric layer end 18 andthe second laminate end 28 through the outer fabric layer conduit 16 andthrough the first laminate end 27 (as illustrated by the arrow on FIG.6A) or pulling the first outer fabric layer end 17 and the firstlaminate end 27 through the outer fabric layer conduit 16 and throughthe first laminate end 28. In this regard, methods according to certainembodiments of the invention comprise turning the intermediate barrierlaminate 50 inside-out such that the outer fabric layer 10 overlies andencircles, at least a portion, of the laminate 20 with the film barrierlayer 21 being located directly or indirectly between the outer fabriclayer 10 and the inner fabric layer 22.

As noted above, the outer fabric layer geometric shape and the laminategeometric shape may be the same or substantially the same, but the outerfabric layer may comprise a 2D surface area that is the same ordifferent than a laminate 2D surface area, for example, when each is inthe non-sealed and/or relaxed state. In certain embodiments, forexample, the outer fabric layer 2D surface area is less than thelaminate 2D surface area, for example, when each is in the non-sealedand/or relaxed state. In this regard, the outer fabric layer in thenon-sealed and/or relaxed state may comprise the same length as thelaminate in the non-sealed and/or relaxed state. In this regard, theouter fabric layer comprises an outer fabric layer length from the firstouter fabric layer end and the second outer fabric layer end and anouter fabric layer width from the first outer fabric layer side thesecond outer fabric layer side. The laminate may comprise a laminatelength from the first laminate end and the second laminate end and alaminate width from the first laminate side the second laminate side, inwhich the outer fabric layer length is the same as the laminate lengthfirst outer fabric layer end.

In accordance with certain embodiments of the invention, the method maycomprise forming the hollow outer fabric layer structure (e.g., a sleeveor tube structure), in which the formed hollow outer fabric structurecomprises a hollow outer fabric layer perimeter, and forming the hollowlaminate structure (e.g., a sleeve or tube structure), in which theformed hollow laminate structure comprises a hollow laminate perimeter,in which the hollow outer fabric layer perimeter is equal to or smallerthan the hollow laminate perimeter when both are in a relaxed and/ornon-stretched state. For example, the hollow outer fabric layerperimeter may comprise from at least about any of the following: 0.1,0.5, 1, 1.5, 2.0, 5 and 10 mm shorter than the hollow laminate perimeterin at least one corresponding point along the article length (or theentire length of the article) in a relaxed and/or non-stretched stateand/or at most about 20, 15, 10, and 5% mm shorter than the hollowlaminate perimeter in at least one corresponding point along an articlelength in a relaxed and/or non-stretched state (or the entire length ofthe article) (e.g., about 0.5 -10 mm, about 1 to about 2 mm). As notedabove, the outer fabric layer seal (formed from bonding a fabric layerto itself) may comprise a stronger seal, as evident by a larger tensilestrength, than the laminate seal. By having the hollow outer fabriclayer perimeter smaller than the hollow laminate perimeter (in a relaxedand/or non-stretched state), according to certain embodiments of theinvention, an initial load applied to the article (e.g., such as a forceexerted by a user's bending elbow exerting force on the article) will behandled by the stronger outer fabric layer seal (e.g., the outer fabriclayer seal tensile strength comprising a value greater than the laminateseal tensile strength as discussed above).

In accordance with certain embodiments of the invention, the outerfabric layer width varies according to a defined profile from a firstouter fabric layer width (e.g., W1 in FIG. 4A) to a second outer fabriclayer width (e.g., W2 in FIG. 4A) along the outer fabric length. Thelaminate width may also vary according to the defined profile from thefirst laminate width (e.g., WL1 in FIG. 5A) to a second laminate width(e.g., WL2 in FIG. 5A) along the laminate length. The outer fabric layerwidth may be the same or smaller than the laminate width alongcorresponding points when the first outer fabric layer end is alignedwith the first laminate end, the second outer fabric layer end isaligned with the second laminate end, or both.

In accordance with certain embodiments of the invention, the outerfabric layer seal comprises an outer fabric layer seal elongation andthe laminate seal comprises a laminate seal elongation, in which theouter fabric layer seal elongation is equal to or less than the laminateseal elongation when subjected to the same tensile force. In certainembodiments, for example, the outer fabric layer seal elongation is fromabout 1 to about 15% (e.g., about 5 to about 10%) less than the laminateseal elongation. In accordance with certain embodiments of theinvention, the outer fabric layer seal elongation may comprise from atleast about any of the following: 1, 2, 3, 4, 5, and 10% less than thelaminate seal elongation and/or at most about 20, 15, 10, and 5% lessthan the laminate seal elongation (e.g., about 5 to about 10%, about 3to about 20%, etc.).

In accordance with certain embodiments of the invention, the outerfabric layer seal comprises an outer fabric layer seal tensile strengthfrom about 5 to about 25% (e.g., from about 10 to about 25%) strongerthan a laminate seal tensile strength. In accordance with certainembodiments of the invention, the outer fabric layer comprises an outerfabric layer seal tensile strength from at least about any of thefollowing: 5, 8, 10, 12, 15, 18, and 20% greater than a laminate sealtensile strength and/or at most about 30, 25, 20, and 15% greater than alaminate seal tensile strength (e.g., about 10 to about 25%, about 15 toabout 25%, etc.).

Methods, in accordance with certain embodiments of the invention,comprise forming a wearable article from the barrier laminate. Wearablearticles according to certain embodiments may comprise a surgical gown,a surgical drape, a sleeve, a pant leg, a shoe cover, a head-piece, afacemask, or a bodysuit.

III. Examples

The present disclosure is further illustrated by the following examples,which in no way should be construed as being limiting. That is, thespecific features described in the following examples are merelyillustrative and not limiting.

Test Methods

Key properties to characterize seal (e.g., a seam including a seal)include, but are not necessarily limited to, the seal maximum striptensile strength and corresponding elongation, seal resistance tohydrostatic pressure of 140 mbar for 1 min (pressure test), sealresistance to penetration of 10% isopropanol & methylene blue solution,and ASTM F1671 “Standard Test Method for Resistance of Materials and inProtective Clothing to Penetration by Blood Borne Pathogens usingPHI-X174 Bacteriophage Penetration as a Test System.”

Tensile Strength & Elongation

The tensile strength and elongation were tested by cutting strips ofmaterial (e.g., nonwoven or bilaminate) perpendicular to the directionof a seam including a seal adhering a first portion of the material to asecond portion of the material being tested. The cut strips were 2.0inch wide and had a minimum length of 6 inch. The cut strips were pulleduntil failure as per standard test method WSP 110.4 (05) using aconstant-rate-of-extension style of testing machine. In this regard, aninitial distance between the jaws of 4.0 inches was used, and a rate ofjaw separation of 11.8 inches per minute (30 cm/min) was also used. Themaximum tensile strength and corresponding elongation were recorded foreach cut sample.

Seal Resistance to Hydrostatic Pressure

For this test, a tube (e.g., hollow structure) of material was opened atthe opposite side from the seam and, a square piece with dimension 7inches×7 inches was cut with the seam located in a position that crossednear the middle of the square piece of cut material. This piece alongwith a retaining screen on top of it was mounted into a hydrostatictester FX3000 sold by TEXTEST AG, Schwerzenbach, Switzerland; and thehydrostatic pressure was increased to 140 mbar at a rate of 60 mbar/min.The retaining screen was a woven polyester mesh, with >50% open area.When the pressure reached 140 mbar, the pressure was maintained therefor 60 seconds. A rating of “pass” indicated no liquid leaking throughthe sample. A rating of “fail” was recorded at the first drop appearingwithin the 60 second period of time after the pressure reached 140 mbar.

Penetration Test

The purpose of this test is to study if a seal (e.g., a seam formed by amaterial and seal adhering the material to itself) leaks when exposed toa solution that simulates the surface tension of blood. For Samples 1and 2 this test was performed on the bilaminate by itself while for theComparative Sample 1 it was performed on the trilaminate. In all cases,however, a 4 inch wide by 10 inch long piece of material was cut andfolded in its middle along the long axis to produce a C-folded piecehaving a width of 2 inches and a length of 10 inches. This C-foldedpiece was then thermal sealed (e.g., formation of a seal) in its middlealong the long axis to form a tubed section that has an internalperimeter of about 2 inches.

An aqueous solution comprising 10% of isopropyl alcohol and 0.2% ofmethylene blue pigment was prepared. The tubed section was bent into aU-shape and filled with the solution until the solution was at 2 inchesfrom the top on both sides of the U-shaped tubed section. The ends ofthe U-shaped tubed section were then pulled together by a paper clip andsuspended in the air. The samples were inspected at time intervals forany sign of the colored solution having penetrated the seam via theseal. When the solution appears to have completely penetrated the seamvia the seal at a first location, the time was recorded as thepenetration time.

Example 1

A sleeve was produced using a spunbond nonwoven and a bilaminate. Thespunbond nonwoven had a 24 gsm basis weight and was made from aformulation that comprised mainly isotactic polypropylene having aviscosity of 35 MFR as measured by the standard test method ISO 1133(230° C. and 2.16 Kg). Such a spunbond nonwoven can be made on Reicofilspunbond production equipment sold by Reifenhauser Reicofil, Troisdorf,Germany. The bilaminate was produced by bonding a breathable monolithicfilm to a SMS (spunbond-meltblown-spunbond composite) nonwoven usingfiberized hot melt adhesive. The SMS nonwoven made of polypropyleneconsisted of a point bonded nonwoven that comprised a layer of meltblownfibers captured between two layers of continuous filaments. The SMSnonwoven had a basis weight of 20 gsm. The adhesive holding the film andthe SMS nonwoven together was a hot melt adhesive that had beenfiberized and applied in a random pattern using typical equipment thatone knowledgeable in the art would be familiar with. This adhesive wasapplied uniformly at a rate of 2 gsm, however, it covered only a smallfraction of the surface. As such, the adhesive did not significantlyimpact the breathability of the bilaminate. The monolithic breathablefilm was produced by a cast process and comprised (i) about 98% of athermoplastic copolyester elastomer from DSM Engineering Plastics,Geleen, The Netherlands, having a MFR of 10 MFR (tested as per standardtest ISO 1133 at 230° C. and under a load of 2.16 Kg) and was selecteddue to its high breathability and ease of processing into a film and(ii) about 2% polyethylene having a MFR of 25 (tested as per standardtest ISO 1133 at 190° C. and under a load of 2.16 Kg).

The above spunbond nonwoven as well as the bilaminate were cut intoisosceles trapezoid shapes, where the shorter base was 12 inches (e.g.,the shorter base is the length of the shorter side that runperpendicular to the line of symmetry) and the longer base was 25 inches(e.g., the longer base is the length of the longer side of the trapezoidthat run perpendicular to the line of symmetry) and the height is 25inches (e.g., the height is defined as the length of a line thatconstitutes the line of symmetry for such trapezoid). The above spunbondnonwoven trapezoid shape was folded along the line of symmetry to form asleeve tube and the overlapping edges were ultrasonically sealedtogether. The sealing pattern consisted of a narrow continuous line andtwo discontinuous lines running parallel to each other. The ultrasonicbonding unit was typical of what is used and should be known by peopleknowledgeable in the art.

The above bilaminate was sealed using an impulse heat sealer machine(model PW3024-545 by Packworld) by folding the trapezoidal shape alongthe line of symmetry and forming a seal along the edge to form a tube.The trapezoid shape was folded such that the film sides of thebilaminate were facing each other. Therefore, the seal for the seam wasaccomplished by fusing those film surfaces to each other in order toform a sleeve tube with an impervious seal (e.g., a seam structureincluding an impervious seal). For this operation, the impulse heatsealer machine was equipped with band shaped heating elements that wereabout 6 mm wide and the sealing conditions comprised (i) a temperatureset point for sealing of 185° C.; (ii) for a sealing time of 3.0seconds; (iii) at 75 psi of seal pressure; and (iv) a 50° C. cool-totemperature.

The sealing of the nonwoven and the bilaminate was done in a way thatboth sleeves had the same inside perimeter when comparing the samepoints along their length. The sleeve tube made from the spunbondnonwoven was inserted into the sleeve tube made from the bilaminate in away that the seams were close and parallel to each other. The two sleevetubes were then turned inside-out (e.g., inverted) to form a sleeveassembly (e.g., an article) suitable for any additional optionalfinishing steps (e.g., adding a sleeve cuff) and incorporated into, forexample, a gown (e.g., by attaching the sleeve tubes to a gown throughstitching or ultrasonic sealing). In this final configuration, thebilaminate sleeve tube formed the inner layer of the sleeve assemblywhile the spunbond nonwoven sleeve tube formed the outside of the sleeveassembly. For this example, the spunbond nonwoven sleeve tube, thebilaminate nonwoven sleeve tube, as well as the final assembly for thesleeve were tested and the results are reported in Table 1.

Example 2

A sleeve was produced using a SMS nonwoven and a bilaminate (e.g., anonwoven-film bilaminate). The SMS nonwoven had a 44 gsm basis weightand was made of polypropylene. The SMS nonwoven comprised a layer ofmeltblown fibers positioned between two layers of continuous spunbondfilaments. This SMS nonwoven was point bonded and was made on a Reicofilspunbond production equipment sold by Reifenhauser Reicofil, Troisdorf,Germany. The bilaminate was made in the same manner as in Example 1.

The SMS nonwoven and bilaminate were cut into isosceles trapezoid shapeslike in Example 1. The above SMS nonwoven was sealed using an impulseheat sealing machine (model PW3024-545 by Packworld) by folding the SMSnonwoven along the line of symmetry and sealing the edge to form a tube.For the formation of the tube, the seal machine was equipped with bandshaped heating elements that were about 6 mm wide and the sealingconditions comprised (i) a temperature set point for sealing of 185° C.;(ii) for a sealing time of 3.0 seconds; (iii) at 75 psi of sealpressure; and (iv) a 50° C. cool-to temperature. The bilaminate wassealed like in Example 1.

The sealing of the SMS nonwoven and the bilaminate was done in a waythat both sleeves had the same inside perimeter when comparing the samepoints along their length. The tube (e.g., sleeve tube) made from theSMS nonwoven was inserted into the tube (e.g., sleeve tube) made fromthe bilaminate in a way that the seams were close and parallel to eachother. The two tubes (e.g., sleeve tubes) were then turned inside-out toform an article (e.g., sleeve assembly) suitable for any additionaloptional finishing steps (e.g., adding a sleeve cuff) and incorporatedinto, for example, a gown (e.g., by attaching the sleeve tubes to a gownthrough stitching or ultrasonic sealing). In this final configurationthe bilaminate formed the inner layer of the sleeve assembly while theSMS nonwoven formed the outside of the sleeve assembly. For this examplethe SMS nonwoven sleeve tube, the bilaminate tube, as well as the finalsleeve assembly were tested and the results are reported in Table 1.

Comparative Example 1

A trilaminate material was created that consisted of a 12 gsmbreathable, fluid impervious monolithic barrier film sandwiched betweena 24 gsm spunbond nonwoven and a 20 gsm SMS spunbond nonwoven, in whichboth nonwovens were made of polypropylene. The nonwoven layers wereindividually adhesively bonded to the film with 2 gsm of fiberized hotmelt adhesive applied in the same manner as in Examples 1 and 2. Theresulting trilaminate was represented as S/film/SMS (i.e.,spunbond/film/spunbond-meltblown-spunbond structure). The monolithicfilm was the same as used for Examples 1 and 2. The nonwovens were, aswas the case for Examples 1 and 2, produced on Reicofil productionlines.

The above trilaminate was sealed using an impulse heat sealing machine(model PW3024-545 by Packworld) by first folding the trilaminatetrapezoid shape along the line of symmetry with the spunbond side (SB)toward the inside and forming a seal along the edge to form a tube. Forthis sample, the impulse heat sealing machine was equipped with bandshaped heating elements that were about 6 mm wide and the sealingconditions comprised (i) a temperature set point for sealing of 197° C.;(ii) for a sealing time of 5.3 seconds; (iii) at 60 psi of sealpressure; and (iv) a 50° C. cool-to temperature. These particularsealing conditions were found after experimentation to be optimal forthis specific construction.

TABLE 1 Pressure Pene- Tensile Elonga- Test tration Test: Part beingN/50 tion 140 mbar × Test F1671 tested mm % 1 min min N = 3 Sample 1 24gsm 32.0  39.0 NA NA NA spunbond sleeve tube Bilaminate 9.7 21.7pass >120 Pass sleeve tube min Assembled 35.9  33.6 pass NA Pass sleevetube Sample 2 44 gsm 33.3  21.8 NA NA NA SMS spun- bond tube Bilaminate15.5  23.1 pass >120 Pass sleeve tube min Assembled 49.2  21.8 pass NAPass sleeve tube Com- Trilaminate 30.38 No pass 35 Fail parative sleevetube Data Sample 1

The test results for key properties of Example 1, Example 2, andComparative Example 1 are summarized in Table 1. The results, as shownin Table 1, illustrate that the sleeve tubes for Examples 1 and 2 (bothmade from a nonwoven) had a stronger seam via the seal formed betweenjoined portions of the nonwoven sleeve tubes as compared to the sleevetubes made from the bilaminate (e.g., film-to-film seal). Additionally,the barrier properties, as expressed by the F1671 and penetration testresults, were superior for Examples 1 and 2 (e.g., illustrative ofcertain embodiments in accordance with the invention) in comparison toComparative Example 1.

These and other modifications and variations to the invention may bepracticed by those of ordinary skill in the art without departing fromthe spirit and scope of the invention, which is more particularly setforth in the appended claims. In addition, it should be understood thataspects of the various embodiments may be interchanged in whole or inpart. Furthermore, those of ordinary skill in the art will appreciatethat the foregoing description is by way of example only, and it is notintended to limit the invention as further described in such appendedclaims. Therefore, the spirit and scope of the appended claims shouldnot be limited to the exemplary description of the versions containedherein.

That which is claimed:
 1. A method of making a barrier laminate,comprising: (i) providing a hollow outer fabric layer structurecomprising an outer fabric layer that is bonded to itself to form anouter fabric layer seal extending from a first outer fabric layer end toa second outer fabric layer end and to form an outer fabric layerconduit; (ii) providing a laminate comprising (a) a barrier film layerand (b) an inner fabric layer; wherein the laminate is thermally bondedto itself via the barrier film layer to define a laminate seal and toform a hollow laminate structure defining a laminate conduit; (iii)encircling the hollow outer fabric layer structure with the laminate;wherein the barrier layer film is located either directly or indirectlybetween the outer fabric layer and the inner fabric layer to form anintermediate barrier laminate; (iv) inverting the intermediate barrierlaminate to form the barrier laminate; wherein the outer fabric layerencircles and overlies the laminate at the completion of the invertingstep.
 2. The method of claim 1, wherein inverting the intermediatebarrier laminate to form the barrier laminate comprises pulling thesecond outer fabric layer end and the second laminate end through theouter fabric layer conduit and through the first laminate end or pullingthe first outer fabric layer end and the first laminate end through theouter fabric layer conduit and through the second laminate end.
 3. Themethod of claim 1, further comprising forming the hollow outer fabriclayer structure by bonding the outer fabric layer to itself to form theouter fabric layer seal.
 4. The method of claim 1, further comprisingforming the hollow laminate structure by bonding the laminate to itselfvia the barrier film layer.
 5. The method of claim 4, wherein the stepof forming the hollow laminate structure is conducted subsequent to thestep of encircling the hollow outer fabric layer structure with thelaminate.
 6. The method of claim 4, wherein the step of forming thehollow laminate structure is conducted prior to the step of encirclingthe hollow outer fabric layer structure with the laminate.
 7. The methodof claim 1, wherein the hollow laminate structure concentricallyencircles the hollow outer fabric layer structure.
 8. The method ofclaim 1, wherein the outer fabric layer seal is at least 10% strongerthan the laminate seal as determined by test method WSP 110.4(05). 9.The method of claim 1, wherein the barrier laminate is devoid of bondsbetween the outer fabric layer and the laminate.
 10. The method of claim1, further comprising attaching the barrier laminate to a separate anddistinct second article via one or more bonds, and the barrier laminateis devoid of bonds between the outer fabric layer and the laminateexcept for the one or more bonds attaching the barrier laminate to theseparate and distinct second article.
 11. The method of claim 1, whereinthe barrier film layer comprises a porous film or a monolithic film. 12.The method of claim 1, wherein the outer fabric layer comprises a firstnonwoven fabric and the inner fabric layer comprises a second nonwovenfabric.
 13. The method of claim 12, wherein the outer fabric layer, theinner fabric layer, or both comprise a spunbond layer.
 14. The method ofclaim 1, wherein the outer fabric layer further comprises a liquidrepellant composition disposed thereon, and wherein the liquid repellantcomprises at least one fluorochemical.
 15. The method of claim 1,wherein the outer fabric layer seal comprises a heat seal, adhesiveseal, ultrasonic seal, mechanical seal, or any combinations thereof. 16.The method of claim 1, wherein the hollow outer fabric layer structurecomprises a cylindrical configuration, a truncated cone configuration,or a truncated triangular configuration.
 17. The method of claim 1,wherein the hollow outer fabric layer structure has a hollow outerfabric layer perimeter and the hollow laminate structure includes ahollow laminate perimeter, and the hollow outer fabric layer perimetercomprises a first value that is larger than the hollow laminateperimeter when the outer fabric layer encircles and overlies thelaminate, and comprises a second value that is equal to or smaller thanthe hollow laminate perimeter when both are in a relaxed andnon-stretched state associated with pre-encircling of the laminate withthe outer fabric layer.
 18. The method of claim 1, wherein the outerfabric layer seal comprises an outer fabric layer seal elongation andthe laminate seal comprises a laminate seal elongation, the outer fabriclayer seal elongation is less than the laminate seal elongation whensubjected to the same tensile force as determined by test method WSP110.4(05).
 19. The method of claim 1, wherein the barrier laminatecomprises a gown, a drape, a sleeve, a pant leg, a shoe cover, or ahead-piece.
 20. The method of claim 1, wherein the outer fabric layerseal comprises a first thermal seal and the laminate seal comprises asecond thermal seal; wherein the outer fabric layer seal is at least 10%stronger than the laminate seal as determined by test method WSP110.4(05).